Introduction: BBQ Grill Heat Shields From Old Roofing Sheet
I want to start by stating that this is my first instructable, so please tell me if I'm doing anything wrong. The heat shields on our BBQ grill started crumbling due to rust last year, and I've been putting off buying new shields. However, yesterday I decided to take matters into my own hands, and create my own diy heat shields.
Supplies
Materials:
- Roofing sheet (or any other type of sheet metal)
Tools:
- Hammer
- Pliers
- Anvil (I used the box of nails in the picture and a plank instead)
- Pen (I used the tip of a rusty knife)
- Angle grinder (or anything to cut metal)
Safety equipment:
- Safety Glasses
- Gloves
Step 1: Flatten the Metal
Use the hammer and anvil to flatten the roofing sheet. If your using normal sheet metal you obviously doesn't need this step
Step 2: Cut a Metal Strip
Use the angle grinder to cut a strip of flat metal to approximately the same width as the old heat shield.
Step 3: Bend the Metal Strip
There are tons of ways you can bend the metal. I used a combination of bending by hand, and lightly tapping with the hammer over the edge of a plank. It doesn't have to be perfect, just enough to place the old shield over the metal strip.
Step 4: Mark Where to Cut
Use the old shield as a template and mark the contours with a sharpie, or if you can't find one, you can use a nail, or the tip of an old rusty knife to scratch the metal.
Step 5: Cut the Pattern
Use the angle grinder to cut the pattern you marked in the previous step. Do this step as carefully as possible. Use your safety equipment, such as fire retardant clothes and safety glasses, and make sure to keep a fire extinguisher nearby just in case. The edges you cut will also be extremely sharp so use gloves, and consider switching from the cutting wheel to a grinding wheel to deburr the edges
Step 6: Bend Out the Vents
Use a pair of pliers to bend out the air vents. Try to get this relatively close to the original, it doesn't need to be perfect but the closer you can get it, the better it'll be. This is also a great place to revisit step 3 and try to get the bend more accurate.
Step 7: Repeat
Repeat all previous steps till you have enough shields and fit them in your grill. This is also a great time to bring out the wirebruch (or the drill wire wheel) and clean up the grill.
![Metal Contest](https://content.instructables.com/F45/MPO1/LIOKVJPE/F45MPO1LIOKVJPE.jpg?auto=webp&crop=1240%2C600&frame=1&width=320)
This is an entry in the
Metal Contest
5 Comments
3 days ago
Great idea, except be sure the metal you use is not galvanized. Steel roofing is probably galvanized.
From Kettlefreaks.com: "Heating a galvanized metal surface releases zinc fumes. These fumes accumulate in the food but are also toxic to breathe."
Reply 2 days ago
Is there any way I can edit the post, or is that necessary?
Reply 2 days ago
Thanks a lot,
I actually didn’t think of this, but you’re totally right. I just looked it up and it is possible to burn off the coating, or you can soak it in vinegar for 24h to de solve the coating. However, I’ll probably try to do it with ordinary sheet metal instead.
3 days ago on Step 7
Great idea. I buy these every 2 years for my grill at some stupid price. This is a nice fix for on the cheep. Good job on your first entry. Semper FI
Reply 3 days ago
Thanks a lot!
Yea, was planing on buying a set for a long time since my parents was starting to use the grill without the shields, just the flame rods, but as you said, the price is stupid. I’m glad you found this useful. Once again, thanks for the feadback